From Single-Sensor Constraints to Multisensor Integration: Advancing Sustainable Complex Ore Sorting

Processing complex ore remains a challenge due to energy-intensive grinding and complex beneficiation and pyrometallurgical treatments that consume large amounts of water whilst generating significant waste and polluting the environment. Sensor-based ore sorting, which separates ore particles based on their physical or chemical properties before downstream processing, is emerging as a transformative technology in mineral processing. However, its application to complex and heterogeneous ores remain limited by the constraints of single-sensor systems. In addition, existing hybrid sensor strategies are fragmented and a consolidated framework for implementation is lacking. This review explores these challenges and underscores the potential of multimodal sensor integration for complex ore pre-concentration. A multi-sensor framework integrating machine learning and computer vision is proposed to overcome limitations in handling complex ores and enhance sorting efficiency. This approach can improve recovery rates, reduce energy and water consumption, and optimize process performance, thereby supporting more sustainable mining practices that contribute to the United Nations Sustainable Development Goals (UNSDGs). This work provides a roadmap for advancing efficient, resilient, and next-generation mineral processing operations.